Panel with decorative simulated inlay and process



D. s. RAMEY 3,537,874

PANEL WITH DECORATIVE SIMULATED INLAY AND PROCESS Nov. 3, 1970 F S R mm G 63:95

hMN ND 29 A A w SAP FILM AND PANEL.

ISEFOIRMI Nq APPLYING FILM To PANEL u2FAcE Q Filed Oct. 23. 1967 Exposl Ne EE-MAINDER OF PANEL Fl mam Nq FnasT AREAS INVENTOR: bAvmSRAME-Y ATTORNEY5 D- S. RAMEY Nov. 3, 1970 PANEL WITH DECORATIVE SIMULATED INLAY AND PROCESS 3 Sheets-Sheet 2 Filed Oct. 23. 1967 INVENTOR. bAvlb S. RAM EY Bar/M664 9 ATTORNEYS D. S. RAMEY Nov. 3 1970 PANEL WITH DECORATIVE SIMULATED INLAY AND PROCESS Filed Oct 23, 196

3 Sheets-Sheet 3 INVENTORI bAvm S. RAMEY .z -14/ ATTORNEYS United States Patent US. Cl. 117-55 17 Claims ABSTRACT OF THE DISCLOSURE A decorative panel, and process of producing the same, wherein a finish-receiving deformable substrate material, such as wood, has on a surface thereof a simulation of an inlay of a contrasting material. This inlay effect is obtained by applying a protective film to the surface of the substrate material and then deforming the same along predetermined lines for obtaining an outline of the configuration of the inlay effect and then stripping the protective film from certain areas of the surface and thereafter subjecting the exposed areas to a finishing operation imparting a first characteristic appearance thereto after which the remaining protective film on the surface is removed and the surface is again subjected to a finishing operation imparting thereto a second characteristic appearance contrasting with the first.

The art of inlay is among those crafts which have long been used to achieve decorative effects for furniture, panels or various other objects. While this art or craft is applicable to many finish-receiving materials, and in the past has been used with materials other than wood, the most widely known and more easily accomplished application in inlay does involve the use of that relatively easily worked material. Any inlay, regardless of materials involved, obtains its characteristic appearance by an incision into the surface of one body of material and the careful fitting, or inlaying, into the incision of a body of material having an appearance which contrasts with that of the background material. The careful cutting and fitting necessary to obtain a substantially continuous and smooth surface have resulted in the art or craft of inlay being largely a manual operation directly reflecting the skill and care of the artisan or craftsman.

With the increasing cost of craft work such as this in recent years, the cost of true inlay decoration has become such that inlay is no longer commonly seen on modestly priced articles, such as lines of furniture intended to be sold in middle or lower price ranges. Even though such decoration is rarely seen on such goods, the decorative effect of inlay is still desired and sought after by the furniture industry, with the principal deterrents being the expense involved and the difiiculty of accommodating a craft operation to production line procedures.

With the foregoing in mind, it is an object of the present invention to provide a process for the production of simulated inlays into the surface of a finish-receiving substrate material such as plywood paneling or the like, which process is particularly adapted for production line manufacturing processes such as are now used in producing moderately priced articles. By following a process as contemplated by the present invention, articles, such as furniture groupings, intended for the moderate and lower price markets may be provided with decoration closely approaching the appearance of a true handcrafted inlay, while being accommodated to production line practices.

A further object of the present invention is to provide a panel of finish-receiving material, such as wood, on

3,537,874 Patented Nov. 3, 1970 which is simulated the appearance of an inlay into the surface of the wood, through the provision of areas of contrasting appearance, contiguous along a line pressed into the surface of the finish-receiving material.

As will become more apparent hereinafter, the process of the present invention contemplates that the finishing procedures which impart distinctive characteristic appearances to the various portions of the finish-receiving surface on which an inlay is simulated may be performed at different times, in different places, and/or by different parties if so desired. Accordingly, it is an object of the present invention to provide a process which may be initiated by a first producer and carried through to completion by an ultimate manufacturer who desires to incorporate into his finished product a panel bearing a simulated inlay. Correlatively, the present invention contemplates that the product of the process may be transferred between manufacturers at a selected one of several intermediate stages, chosen to suit the convenience of the party finally incorporating the inlay simulation into a finished product.

:Some of the objects and advantages of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which- FIG. 1 is a fiow chart schematically illustrating the progression of steps in the method of this invention;

FIG. 2 is a somewhat schematic representation, in perspective, of the application of a protective film to a wooden substrate panel;

FIG. 3 is a view similar to FIG. 2 of the deformation of a film and the panel protected by the film along design defining lines;

FIG. 4 is an enlarged cross-sectional view through a panel and film, taken generally along the line 4--4 in FIG. 3;

FIG. 5 is a view similar to FIGS. 2 and 3 of the exposure of a first area of the surface of the panel of FIG. 3;

FIG. 6 is a view similar to FIGS. 3 and 5 of the subjection of exposed areas of the panel of FIG. 5 to a first finishing operation;

FIG. 7 is a view similar to FIG. 5 of the exposure of the remainder of the surface of the panel of FIG. 6;

FIG. 8 is a view similar to FIG. 6 of the subjection of the panel of FIG. 7 to a second finishing operation;

FIG. 9 is a view similar to FIG. 4 through a panel during the first finishing operation, taken generally along the line 99 in FIG. 6; and

FIGS. 10 through 14 illustrate a sequence similar to that of FIGS. 5 through 9 but obtaining a reverse effect of contrasting appearances, FIG. 10 corresponding to FIG. 5; FIG. 11 to FIG. 6; FIG. 12 to FIG. 7; and FIG. 13 to FIG. 8. FIG. 14 is an enlarged sectional view through a panel of FIG. 4 as stripped in accordance with FIG. 10 in order to obtain the reverse effect, and is taken generally along the line 14-14 in FIG. 10.

Referring now more particularly to the drawings, the process of the present invention is there illustrated both by block. diagram flow chart (FIG. 1) and by more detailed illustrations of sample panels undergoing the steps of the process (FIGS. 2-14). The process contemplated by the present invention, the various intermediate products thereof, and the final product will be described in greater detail hereinafter, together with certain ramifications of the process and details of the manner in which it is practiced.

At the outset, it should be understood that the detailed discussion will proceed with reference to sample panels 15 of wood, but that the example of wood is chosen for illustrative purposes only. It is recognized that the proc- 3 ess of the present invention may be applied to any substrate material adapted to receive a finish and into which a line of deformation (herein also referred to as a groove) may be pressed, as described hereinafter. Accordingly, the present invention is not to be limited by the discussion herein with reference to the wood panels 15.

Broadly, the present invention contemplates producing, on the surface of a finish-receiving substrate material such as wood and the like, a simulation of an inlay into the surface by a procedure involving application of a protective film to a surface on which an inlay is to be simulated, then the deformation of the protective film and the surface of the material along predetermined lines which outline the configuration of a simulated inlay so as to at least weaken the film and to groove the material along those lines which ultimately will separate areas of contrasting appearance. Thereafter, predetermined first areas of the surface, contiguous to the groove, are exposed by stripping away the protective film which at least parts easily along the lines of deformation, if it has not been cut through, and the thusly exposed first areas of the surface are subjected to a finishing operation to impart thereto a first characteristic appearance while the protective film remaining on the other areas of the surface protects those other areas from the effect of the initial finishing operation. Thereafter, the remaining area of the surface is exposed by stripping the remainder of the protective film therefrom and the thusly exposed surface is subjected to a finishing operation to impart to the later exposed areas of the surface a second characteristic appearance contrasting with the characteristic appearance of the first areas. By following this procedure, from start to finish, the contrast between areas subjected to only the second finishing operation and the first areas, together with the separation of those areas by the grooves formed at the time that the protective film and substrate are deformed, simulates the appearance of an inlay into the surface.

The final product of following this process, through all of the above steps, is a panel having a surface with at least one groove pressed into the surface along predetermined lines outlining the configuration of a simulated inlay, separating the surface into at least two contiguous areas and having rounded shoulder portions adjacent a central depression. Further, the panel has finishes on the surface which impart to the two areas thereof at least two contrasting characteristic appearances, so that the contrast between the two areas, the separation thereof by the groove and the contrast between the shoulder portions along the groove simulate the appearance of inlay into the surface. As pointed out more fully hereinafter, the sequence of the steps in this method may be interrupted at one of several points, to permit a manufacturer who will ultimately complete the final product to more readily fit the production of simulated inlays into an established production line routine.

The sequence of operations described broadly above, with reference to a general flow sheet block diagram, will become more clear by reference to a more representational series of illustrations (FIGS. 2-9) wherein the steps of progression in producing a simulated inlay on the surface of a substrate panel are illustrated. First, the panel 15 has a protective film 16 applied thereto, as by being passed adjacent a pressure roller 17 with the protective film 16 being advanced from a storage roll 18 thereof to be pressed into contact with a surface 20 of the panel 15 (FIG. 2). In one embodiment of the present invention presently being commercialized, the protective film is a self-adhering or contact-adhering sheet of paper masking tape carrying a surface coating of adhesive. Such masking tapes are available in a great variety of stickiness or tackiness, and it is preferred to select a tape carrying an adhesive which is a compromise between positive sealing and ready stripability, as pointed out more fully hereinafter. While paper masking tape is preferred for one commercial embodiment presently in use, it is contemplated that the protective film may be of any type which readily adheres to the surface 20 of the panels 15 and yet may be peeled or otherwise removed therefrom without affecting adversely the affinity of the surface for a subsequent finishing operation. Thus, the protective film may be a film of plastic, applied by spraying, or a film of metallic foil adhered by any suitable adhesive and may be removed by chemical rather than purely mechanical means. Depending upon such choices of film, certain special finishing techniques and resultant characteristic appearances are available, as pointed out more fully hereinafter.

Subsequent to the application of the protective film to the surface 20 of the panel 15, the film and surface are deformed by pressing a steel rule die 21 into the plywood panel 15 (FIG. 3). The steel rule die 21 may be configured to assume any desired design configuration, of which one example is shown, and is sharpened with a relatively blunt shoulder or tapered edge portion. Accordingly, when the steel rule die is pressed into an easily cut protective film such as masking tape and the material of the plywood panel 15, the die cuts through the protective film 16 and penetrates into the surface 20' along predetermined lines which outline the configuration of the simulated inlay. Should the film used be less readily cut, care must be taken that the deformation of the film causes such weakness along the line of deformation that the film is readily stripable from adjacent areas of the panel as described hereinafter. Due to the relatively blunt shoulder of the steel rule die, the material of the plywood panel 15 is deformed or grooved immediately adjacent the cut line as the protective film is cut (FIG. 4). The groove 22 thus formed in the surface 20 of the plywood panel 15 is obtained without the removal of material from the panel, lies immediately along those lines which ultimately will separate areas of contrasting appearance, and will subsequently, as pointed out hereinafter, contribute to simulation of the appearance of an inlay into the surface.

Thereafter, a portion of the surface 20 is exposed, by stripping a portion of the protective film therefrom along the grooves formed in the film and the plywood panel 15 (FIG. 5). Due to a distortion of the film during the deforming step, which causes the film to be rolled downwardly in the shoulder portions of the groove 22 imediately adjacent to the central depression of the cut lines, the stripping of the protective film from the area of the panel 15 exposes one shoulder portion immediately adjacent the out line, inasmuch as the area from which the protective film is stripped is contiguous to the groove 22 (FIG. 9).

Thereafter, the panel 15 is subjected to a finishing treatment, which may be a staining operation (as in FIG. 6), a sealing operation, scoi'ching by the application of heat, printing of a disparate grain pattern or any other finishing operation which imparts a first characteristic appearance to the areas exposed during the operation. As pointed out more fully hereinafter, the area stripped and the particular finishing operation to which it is subjected preferably are selected with a view to the end effect sought.

After the first areas of the surface have received the desired finish, the remainder of the area of the panel 15 is exposed by stripping the remainder of the protective film therefrom (FIG. 7), and then the surface 20 is subjected to a finishing operation to impart to the later exposed areas of the surface the second characteristic appearance contrasting with the characteristic appearance of the first areas (FIG. 8). In order to accommodate modern production practices, this invention contemplates that the entire exposed area of the surface 20 will be subjected to the second finishing operation, and that operation is preferably one that imparts to the later exposed areas of the surface a characteristic appearance lighter in color than the characteristic appearance of the first areas. By selecting the sequence of stripping of the various areas and the finishing operations so that the first exposed areas receive a darker appearance, the subsequent application of a finish yielding a lighter characteristic appearance results in a visual contrast between the areas. It is this visual contrast between areas subjected to only the second finishing operation and the first areas and the separation of those areas by the grooves having rounded shoulders which simulates the appearance of an inlay of lighter material into the surface of a darker material.

In particular, a panel 15 and protective film 16 adhered thereto and grooved as shown in FIG. 3 may be stripped and finished to obtain a reverse effect from the visual contrast apparent in the finished product of FIG. 8. Such a reversal results from the sequence of FIGS. -14, wherein the area of the panel which was subjected to the initial finishing operation as described above is shielded by the protective film 16 during the corresponding finishing operation (FIGS. 11 and 14) during the reverse procedure. Thereafter, the remaining areas are exposed (FIG. 12) and given a lighter finish (FIG. 13) to result in a final product giving the appearance of an inlay of darker material into a background of lighter material.

The sequence of stripping and finishing operations thus may be selected to feature either a background area or a design area as having a darker toned appearance. Further, if a metallic treatment is desired, for example, it may be applied either to a background or to a design area. Scorching by the application of heat, the printing on of disparate wood grain effects, or distressing may similarly be applied to selected areas if desired.

The flexibility of these effects is particularly apparent in conjunction with modern production line practices in the manufacture of furniture. In such practices, furniture pieces being constructed are handled on an assembly line basis, and are finished during movement along the line. A manufacturer of furniture having such an operation may, if he chooses, obtain panels from a supplier who has performed the steps of applying the protective film, cutting the film and grooving the panel, stripping first areas, and finishing the thusly exposed first areas. The furniture manufacturer then may take such intermediate products and, by stripping the remaining background areas, insert the panel directly into furniture pieces moving on his own line and complete the simulation of the inlay by applying the second finish. The same manufacturer, desiring a special effect, may purchase an intermediate product from his supplier at any stage after the application and deformation of the protective film. Thus, should the manufacturer desire a special visual contrast of appearance between the inlay and background areas on the panel, he may choose to obtain an intermediate product where no stripping has taken place, in order to permit storing the product while retaining it clean. Further, the manufacturer may choose a panel which has been cut, grooved and stripped in predetermined first areas of the surface, without any finishing step having taken place. Any of these possibilities, and still others, may be worked out within the scope of the present invention, and are contemplated by the present invention.

In the drawings and specification there have been set forth preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. A method of producing, on the surface of a finish receiving deformable substrate material such as wood, a simulation of an inlay comprising the steps of:

applying a protective film to a surface of the substrate,

then

deforming the protective film and the surface of the substrate along predetermined lines of deformation outlining the configuration of a simulated inlay, then exposing predetermined first areas of the surface contiguous to the predetermined lines of deformation by stripping the protective film from such areas of the surface, then subjecting the thusly exposed first areas of the surface to a finishing operation imparting a first characteristic appearance thereto, and thereafter exposing the entire area of the surface by stripping the remainder of the protective film therefrom, and then subjecting the thusly exposed surface to a finishing operation imparting thereto a characteristic appearance contrasting with the first characteristic appearance of the first areas to thus form a simulated inlay.

2. A method according to claim 1 wherein the step of applying a protective film comprises adhesively securing a thin sheet to the substrate surface.

3. A method according to claim 1 wherein the step of applying a protective film comprises the application of an adhesive coated paper sheet to the substrate surface.

4. A method according to claim 1 wherein the step of deforming the protective film and the surface of the substrate comprises cutting through the film and pressing into the surface of the substrate so as to form therein a groove having at least one rounded shoulder portion.

5. A method according to claim 1 wherein the step of deforming the protective film and the surface of the substrate comprises pressing into the surface of the substrate so as to form therein a groove having at least one rounded shoulder portion, and depressing the film into the groove so as to shield the rounded shoulder portion during a subsequent finishing operation so that the characteristic appearances thereafter imparted to the areas of the surface extend downwardly into the groove.

6. A method according to claim 5 wherein the steps of pressing into the surface of the substrate and depressing the film into the groove thus formed are such that the groove has two rounded shoulders and both of the shoulders are shielded by the film.

7. A method according to claim 1 wherein one of the steps of subjecting areas of the surface to a finishing operation includes applying a stain to the then exposed areas of the surface.

8. A method according to claim 1 wherein each of the steps of subjecting areas of the surface to finishing operations includes applying a stain to the areas of the surface exposed during the respective step.

9. A method of preparing a surface of a finish receiving deformable substrate material such as Wood for the subsequent production thereon of a simulation of an inlay comprising the steps of:

appkllying a protective film to a surface of the substrate,

en deforming the protective film and the surface of the substrate along predetermined lines of deformation ofirtlining the configuration of a simulated inlay, and t en exposing predetermined first areas of the surface contiguous to the predetermined lines of deformation by stripping the protective film from such areas of the surface,

so that the surface may thereafter be subjected to successive first finishing, exposure of the entire area of the surface, and second finishing to provide contrasting characteristic appearances to areas which are contiguous along said predetermined lines of deformation to simulate the appearance of an inlay.

10. A method according to claim 9 wherein the step of applying a protective film comprises adhesively securing a thin paper sheet to the substrate surface.

11. A method according to claim 9 wherein the step of deforming the protective film and the surface of the substrate comprises cutting through the film and pressing into the surface of the substrate so as to form therein a groove having at least one rounded shoulder portion.

12. A method according to claim 9 wherein the step of deforming the protective film and the surface of the substrate comprises pressing into the surface so as to form therein a groove having at least one rounded shoulder portion and depressing the film into the groove so as to shield the rounded shoulder portion during a subsequent finishing opera-tion so that the characteristic appearances thereafter imparted to the areas of the surface extend downwardly into the groove.

13. A method of preparing a surface of a finish receiving deformable substrate material such as wood for the subsequent production thereon of a simulation of an inlay comprising the steps ,of

applying a protective film to a surface of the substrate,

and then deforming the protective film and the surface of the substrate along predetermined lines of deformation outlining the configuration of a simulated inlay,

so that predetermined areas of the surface contiguous to the predetermined lines of deformation may thereafter be exposed by stripping the protective film therefrom and the surface may thereafter be subjected to successive first finishing, exposure of the entire area of the surface, and second finishing to provide contrasting characteristic appearances to areas which are contiguous along said predetermined lines of deformation to simulate the appearance of an inlay.

14. A method according to claim 13 wherein the step of applying a protective film comprises the application of an adhesive coated paper sheet to the substrate surface.

15. A method according to claim 13 wherein the step of deforming the protective film and the surface of the substrate comprises cutting through the film and pressing into the surface so as to form therein a groove having at least one rounded shoulder portion.

16. An article of finish receiving deformable material such as wood prepared for subsequent production of a simulated inlay thereon, and comprising a panel having a substantially planar surface,

said panel having at least one groove outlining the configuration of an inlay to be simulated thereon and separating said surface into at least two substantially planar are-as contiguous along said groove, said groove having at least one rounded shoulder, and

a protective film covering one of said at least two areas,

and said rounded shoulder of said groove,

the other of said at least two areas being exposed and adapted to be finished with a first characteristic appearance, said protective film being adapted to be removed from said one area to expose the surface of said one area to adapt the same to be finished with a second characteristic appearance contrasting with the appearance of said other area so as to simulate the appearance of an inlay on said surface.

17. An article of finish receiving deformable material such as wood prepared for subsequent production of a simulated inlay thereon, and comprising a panel having a substantially planar surface, said panel having a groove outlining the configuration of an inlay to be simulated and separating said surface into at least two areas contiguous along said groove, and

a protective film covering said surface and extending into said groove and comprising at least two sections corresponding to said at least two areas, said film sections being adapted to be successively independently removed to expose the area therebeneath to adapt the areas to successive contrasting finishing operations to simulate an inlay.

ALFRED L. LEAVI'IT, Primary Examiner A. GRIMALDI, Assistant Examiner 

